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HDST Mirror Technology

Assessment

Gary Matthews

Director of Astronomy Systems

Harris Corporation

Phone: 585-269-6511

Cell: 585-278-7252

Gary.Matthews1@harris.com

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Agenda

Mirror Materials Assessment for 10+m telescope

– Telescope will be segmented, but does segment size

drive the science?

Industry Mirror Manufacturing Infrastructure

– What are the current industry standards?

General Mirror Quality Assessment

– What is the current TRL/State-of-the-Art?

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Mirror Material Assessment

• Current mirror material

available for space qualified

applications

– Aluminum

– Beryllium

– SiC

– Glass Ceramics (Zerodur, Astro

Sitall, ClearCeram, etc)

– Glass (Fused Silica, ULE®)

• Aluminum and Beryllium are

not applicable to this mission

• The lower CTE materials have

advantages and disadvantages

JWST HDST

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Material Factors

The glass ceramics will be machined mirrors or thin

active face sheets with an open back

– Stiffness and actuator density will be factors

– On-orbit simplicity and graceful degradation is important

• Less things to go wrong

• Minor failures have small impact performance

Mirror stability will be critical for mission success

– 20pm over 10 minutes

– Comes down to trade between CTE and conductivity

– Trade likely comes down to ULE® and SiC

Mirror quality (~5nm RMS surface) and rate of

production are key trades

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Segment Size

JWST segment size is 1.3m flat-flat

Larger segments are within the trade space to a limit

– Handling risk

– Areal density will increase with size

Likely will want to limit on-orbit correctability to minimize

adding new mid and high spatial frequency errors and

stability concerns

– Manufacture a high quality mirror that requires minimal adjustment

on-orbit

– Low order thermally induced figure errors and minor RoC correction

Segment size will likely want to be between 1.3m and 2.0m

– For glass segments, ~JWST size would enable two mirror blanks to

be manufactured in parallel in existing facilities

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ULE® State-of-the-Art and TRL

Multi Mirror System

Demonstration (MMSD)

Program advanced the TRL of

ultra-lightweight mirror

segments

– 4 new, 10kg/m2 segments

manufactured

– AMSD reused and refigured to

MMSD specification

Optical and environmental

qualification testing performed

5

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Demonstrations of ULE® Solution

MMSD continued to drive the enhance the TRL level for future missions

A. OTM PMSA (Optical Test Model) – Mirror is existing 1.4m AMSD mirror

refinished for MMSD

– New MMSD mounts, actuators,

reaction structure, elec, controls

– 0-G figure and figure control

demonstrated via optical test with

both 10 and 16 FCA configurations

B. Mirror Segment B – New full size MMSD mirror

– 0-G optical finishing demo

– Finished to 16 nm RMS WFE (no

actuation)

C. Mirror Segment C – New full size MMSD mirror

– Finished thru LTS (100 um PV)

– Mounted & tested to high level random

vibe & shock

D. Mirror Segment D – New full size MMSD mirror

– Completed thru plano fusion

E. Mirror Segment E – New full size MMSD mirror

– Completed thru plano fusion

Key validations achieved

on each of these 10kg/m2

mirrors

Production

rate on 3.5

week centers

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Predictable figure convergence

builds schedule confidence

15.318.842

528

68

0

100

200

300

400

500

600

16-Jan-09 28-Jan-09 9-Feb-09 16-Feb-09 19-Feb-09

Seg

men

t W

F E

rro

r (n

m R

MS

)

Start point

• All spatial frequencies included in WF

(i.e. no filtering) (501 x 501 array)

• RoC meets spec

Mirror Zero-G WFE = 15.3 nm RMS

15.3

Note: All plots are on different color scales

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Recent advances in manufacturing

will enhance HDST

TMT will add industrial capability to test and finish

off-axis parabolic segments

– 574 segments will start production soon

– Harris has plans to be able to ion figure up to 5

segments simultaneously

Harris Capture Range Replication (CRR) IR&D has

potential to dramatically reduce processing time of

ultra-lightweight mirror segments

– Reduces processing time by ~50%

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CRR results

Designed and built mandrel to demonstrate replication of a 250mm spherical mirror with a center hole. Successful replication with a resulting figure error of ~6.5μm P-V

(~1μm RMS), and <3μm P-V from mandrel shape. Demonstrated potential to eliminate early processing steps

(generation, rough shaping, grind) and go directly to minor MRF polish and then to final ion figuring

Note low order

errors which

are easy to

remove

9

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AOX

1

Proven Actuator Technology Ready for HDST

Delivered Deformable/Active Mirrors:

• WFPC2 Articulating Fold Mirrors – helped restore HST, on-orbit for 15+ years

• Keck 10m - 2x349ch deformable mirrors

• Gemini 8m - 177ch deformable mirror

• Palomar 5m – PALM 3000: Extreme Adaptive Optics including 4300+ channel deformable mirror enabling Hale to image exoplanets

• MPIA 3m – 349ch

• Mt. Wilson 2.5m – 349ch

• Big Bear Solar Observatory 1.6m – 3x349ch ( example image below right)

• DKIST 4m – 1600 ch thermally managed

In Development• Thirty Meter Telescope – cold temp DMs

• WFIRST Coronagraph – 2300 ch space qualified

• Enabled JPL-HCIT to reach contrast goal of 10E-10

Articulating Fold Mirror

Credit: BBSO /NJIT

Ground-based image of Sunspot Chromosphere

Image created using AOX deformable mirrorsWFIRST Prototype DM

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AOXAOX Silicon Carbide Material Properties

SiC manufacturing maturity opens up new design space for telescope and optic

design, manufacturing, and operation

SiC ranks highest on structural and

thermal figures of merit for common

substrate materials

Sectional stiffness tailored to meet both weight, stability, and stiffness requirements

Areal densities ~8 kg/m² maintained even as mirror size increases

Mirrors can be fully active, partially active or fully passive; polished or replicated optics

High stiffness-to-weight ratios and excellent long-term dimensional stability for substrate, optical bench, and metering structure use

1.2 m SiC SubstrateStiffness Increases

Weig

ht Incre

ases

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AOXMonolithic SiC StructuresMonolithic Optical Bench

3

• Pathfinder optical bench supporting potential space-based coronagraph missions

• Cast using a single graphite mold and our proprietary fugitive core process

• Bench is just over 1 meter long and approximately 30 centimeters tall and 50 cm wide

• Weighs just over 8 kilograms

• Dimensionally stable, lightweight, and stiff

AOX fabricated this all-SiC optical

bench as a single-cast part to

maximize stiffness to weight ratio

and minimize alignment complexity.

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AOXAdvanced Active Hybrid Mirror (AAHM) OverviewReplicated Optics Enable Affordable Segmented Telescopes

Lightweight

Sic

Substrate

Surface

Parallel

Actuators

Kinematic

Mount

Nanolaminate

Optical

Surface

• Advanced Active Hybrid Mirror (AAHM) technology:

a new paradigm for large optical systems

– Nanolaminate optical replicated surface eliminates the need for

polishing : demonstrated production on 6 week centers

– Lightweight SiC substrates provide high stiffness and

dimensional stability at remarkably low areal densities with

apertures up to 2.4m.

– Surface Parallel Actuation with discrete PMN actuators

integrated into SiC rib structure eliminates need for reaction

structure

– Full environmental qualification completed

• Advantages of AAHM

– Reduced fabrication times result in reduced segment, system and programmatic costs

– Active control enables correction for gravity and thermal errors reducing complexity of system performance verification

– SiC high stiffness and strength enables scaling of lightweight substrate designs that can survive launch loads

– Achieve lighter area density enabling scaling to larger apertures

– SiC “fugitive core” casting and nanolaminate optical replication processes enable production fabrication

Replication = Faster builds, less $$. Active = more capabilities, less $$

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Technology Development

Basic concepts have been demonstrated in ULE® to achieve

better than 20nm RMS WFE in a short period of time

– The mirror requirement may require 5nm RMS surface quality

Further leverage will be gained from near-term ground based

observatories production

– Additional metrology development required to produce a repeatable test

set capable of sub-3nm RMS surface measurements

Technology development still needed

– Process harden CRR for size and production to achieve a 5nm RMS

surface mirror at production size and rate

– Edges are always a worry with any mirror

– Force and sub-nm displacement actuators have been built but robust

qualification program required

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